Impact device and methods of making and using the same

ABSTRACT

In an embodiment, an impact device comprises: a metal component comprising greater than or equal to three walls forming a metal component channel; and a plastic component having a honeycomb structure with a plurality of walls defining comb channels therein. The combs channels are oriented perpendicular to at least one of the three walls, and the plastic component is inseparable from the metal component without damage to at least one of the metal component and the plastic component. A wall of the metal component can comprise an aperture, and wherein plastic material from the plastic component is located in the aperture.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/939,374, filed on Nov. 4, 2010, now U.S. Pat. No. 8,336,933, which isherein incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates generally to an energy absorbing devicefor use in a vehicle, for example, to reduce vehicle damage.

Bumper systems generally extend widthwise, or transverse, across thefront and rear of a vehicle and are mounted to rails that extend in alengthwise direction. Many bumper assemblies for an automotive vehicleinclude a bumper beam and an injection molded energy absorber secured tothe bumper beam with a fascia covering the energy absorber.

Beneficial energy absorbing bumper systems achieve high efficiency bybuilding load quickly to just under the load limit of the rails andmaintain that load constant until the impact energy has been dissipated.Energy absorbing systems attempt to reduce vehicle damage as a result ofa collision by managing impact energy absorption. Bumper system impactrequirements are set forth by United States Federal Motor Vehicle SafetyStandards (US FMVSS), Canadian Motor Vehicle Safety Standards (CMVSS),European EC E42 consumer legislation, EuroNCAP pedestrian protectionrequirements, Allianz impact requirements, and Asian PedestrianProtection for lower and upper legs. In addition, the InsuranceInstitute for Highway Safety (IIHS) has developed different barrier testprotocols on both front and rear bumper systems. These requirements mustbe met for the various design criteria set forth for each of the variousautomotive platforms and car models. If there is even very limiteddamage to any component of the frame of the vehicle, costs of repairingthe vehicle can escalate dramatically.

This generates the need to develop low cost, lightweight, and highperformance energy absorbing systems that will deform and absorb impactenergy to ensure a good vehicle safety rating and reduce vehicle damagein low speed collisions. Different components due to their inherentgeometry and assembly requirements need different energy absorberdesigns to satisfy the impact criteria. Therefore, the automotiveindustry is continually seeking economic solutions to improve theoverall safety rating of a vehicle. Hence, there is a continual need toprovide a solution that would reduce vehicle damage and/or enhance avehicle safety rating.

BRIEF DESCRIPTION

Disclosed, in various embodiments, are energy absorbing devices that canbe used in conjunction with various vehicle components.

In an embodiment, an impact device comprises: a metal componentcomprising greater than or equal to three walls forming a metalcomponent channel; and a plastic component having a honeycomb structurewith a plurality of walls defining comb channels therein. The combschannels are oriented perpendicular to at least one of the three walls,and the plastic component is inseparable from the metal componentwithout damage to at least one of the metal component and the plasticcomponent. A wall of the metal component can comprise an aperture, andwherein plastic material from the plastic component is located in theaperture. The device can be located in a vehicle to prevent damage tothe body in white upon impact.

In one embodiment, a method of making an impact device can comprise:forming a metal component comprising greater than or equal to threewalls forming a metal component channel; forming a plastic component;and flowing plastic through an aperture in the metal component. Theplastic component has a honeycomb structure with a plurality of wallsdefining comb channels therein wherein the comb channels that areoriented perpendicular to at least one of the three walls, and theplastic component is inseparable from the metal component without damageto at least one of the metal component and the plastic component.

These and other non-limiting characteristics are more particularlydescribed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings wherein likeelements are numbered alike and which are presented for the purposes ofillustrating the exemplary embodiments disclosed herein and not for thepurposes of limiting the same.

FIG. 1 is a front view of a metal component of an energy absorbingdevice.

FIG. 2 is a front view of an energy absorbing device comprising a metalcomponent and a plastic component.

FIG. 3 is a front view of an energy absorbing device comprising a metalcomponent and a plastic component.

FIG. 4 is a front view of a metal component of an energy absorbingdevice.

FIG. 5 is a front view of a plastic component of an energy absorbingdevice.

FIG. 6 is a front view of an energy absorbing device comprising a metalcomponent and a plastic component.

FIG. 7 is a front view of a plastic component of an energy absorbingdevice.

FIG. 8 is a front view of a plastic component of an energy absorbingdevice.

FIG. 9 is a front view of an energy absorbing device comprising a metalcomponent and a plastic component.

FIG. 10 is perspective view of an energy absorbing device comprising ametal component and a plastic component.

FIG. 11 is a front view of an energy absorbing device comprising a metalcomponent and a plastic component.

FIG. 12 is a side profile taken along line D-D in FIG. 11 of an energyabsorbing device comprising a metal component and a plastic component.

DETAILED DESCRIPTION

Disclosed herein, in various embodiments, are energy absorbing deviceswhich can be used in conjunction with vehicle components, e.g., tominimize the damage suffered during an impact. The energy absorbingdevices can comprise a metal component and a plastic component (e.g.,thermoplastic), which can be manufactured utilizing various co-moldingprocesses to provide a single piece assembled unit (e.g., integrallyformed metal component around the plastic component).

Attempts have been made to provide bumpers for automotive vehicles,which could be able to absorb a major portion of impact energy during acrash, including impact energy absorption devices made of alveolarstructures more commonly referred to as “honeycomb”. The combs of thestructure can be any polygonal or rounded shape, such as circular, oval,square, rectangular, triangular, diamond, pentagonal, hexagonal,heptagonal, and octagonal geometries as well as combinations comprisingat least one of the foregoing geometries.

Metal honeycombs, however, have good energy absorption characteristicsand good creep performance, but involve very high manufacturing cost,and generally weigh more than plastic honeycombs. Plastic honeycombs canbe made by gluing extruded plastic tubes together or injection moldingthe plastic honeycombs. The extruded plastic honeycombs involve highcost and possess limited fields of application due to relatively thinwalls. For example, with extrusion processes it can be difficult toproduce thicker walls (e.g., greater than about 2 millimeters (mm)), asplastic walls thicker than about 2 mm can undergo sagging which couldresult in the profile and the pitch of the honeycomb becoming distorted,while the injection molded plastic honeycombs are relatively cheaper buttheir impact energy absorption performance is inferior. Both extrudedand injection molded honeycombs have inferior creep performance comparedto the metal honeycombs and undergo significant deformation in thetransverse direction (e.g., gravitational load) while used to supportrelatively heavier components (e.g., bumper beams). Generally, theenergy absorbing devices support a metallic bumper beam. Due to thegravitational load of the beam weight, the energy absorbing devices havethe tendency to deform over a period of time and/or when exposed tohigher temperatures. Beam deflection (i.e., creep) of greater than orequal to about 4 mm may not be acceptable by original equipmentmanufacturers (OEMs).

The present application combines a plastic honeycomb structure with ametal support disposed around greater than or equal to 3 sides thereofto produce the energy absorber device, e.g., a crash can (also known asa crash box). The honeycombs form channels that can be oriented, forexample, parallel or perpendicular to one or more of the metal supportwalls.

The metal component can comprise greater than or equal to three walls(e.g., an open or closed structure). Open structure has three walls thatform a channel with at least three open sides (e.g., two opposing wallsand a connecting wall), while a closed structure has greater than orequal to four walls (comprising two sets of opposing walls that connectto form less than or equal to two open walls). Generally, closedstructures provide an increased stiffness to weight ratio and bettercreep performance (i.e., less deflection or deformation) compared to anopen structure. An open structure can facilitate ease of tooling,however.

The metal component can optionally comprise crush initiators. The crushinitiators (e.g., stress points) can serve as weak points in the metalcomponent which will crush more readily than other areas of the metalcomponent, thereby enabling the manner of crushing as well as the angleof greatest energy absorption to be controlled (e.g., chosen andmanufactured into the energy absorbing device). The crush initiator(s)can be located anywhere on the metal component. In some embodiments,crush initiator(s) are located at the junction of adjoining walls (e.g.,at the corner(s) of the metal component). The crush initiators can beopening(s) (e.g., hole(s), slit(s), or other opening) and/orindentation(s). The size and shape of the crush initiators is dependentupon the desired crush characteristics. The crush initiator(s) enablefacile tuning of the energy absorbing device. The crush initiators canalso provide provisions for interlocking between the metal component andthe plastic component during processing (e.g., during a co-moldingprocess of the metal component and the plastic component). The number ofcrush-initiators located on the metal component is not limited andvaries depending upon the length of the energy absorbing device.Desirably, a longer energy absorbing device will have a larger number ofcrush initiators, while a shorter energy absorbing device will have asmaller number of crush initiators. A hole located in a metal component(e.g., a mounting hole) can also serve as crush initiator. However, useof a hole such as a mounting hole as a crush initiator can result in asignificant reduction in the stiffness of the crash can. Crushinitiators such as an engineered depressions or beads in the metalcomponent can assist in initiating crushing with a minimal reduction incomponent stiffness.

In addition to enabling predetermined crushing, e.g., tuning, of theenergy absorbing device, if the crush initiator(s) comprise an opening,it can also serve as an anchor for the plastic component in the metalcomponent. When the plastic component is attached into the metalcomponent, the components can be attached together via the opening(s),e.g., with plastic, bonding agents, and the like. Desirably, the plasticcomponent is co-molded into the metal component such that some plasticpasses into the opening and solidifies, bonding the components together.Alternatively, or in addition to the crush initiator opening(s), themetal component can comprise attachment aperture(s) that can be locatedin a cavity of the metal component (e.g., wherein the cavity is aprotrusion into the metal component channel, toward the plasticcomponent). The attachment aperture(s) can align with thermoplasticpiece(s) on a surface of the plastic component, e.g., such that, duringassembly, the thermoplastic of the plastic portion can move through theaperture, into the cavity and solidify, thereby binding the metalcomponent to the plastic component through the aperture(s).

Exemplary characteristics of the energy absorbing device include hightoughness/ductility, thermal stability, high energy absorption capacity,a good modulus-to-elongation ratio, and recyclability, among others,wherein “high” and “good” are intended to mean that the characteristicat least meets vehicle safety regulations and requirements for the givencomponent/element. The metal component can comprise any metal(s) ormetal alloy(es) having the desired characteristics, e.g., structuralintegrity, stiffness, and so forth. Some possibly metal componentmaterial(s) include aluminum, steel, titanium, chrome, magnesium, zinc,as well as combinations comprising at least one of the foregoingmaterials.

The plastic component can comprise any thermoplastic material orcombination of thermoplastic materials that can be formed into thedesired shape and provide the desired properties. For example, thethermoplastic material should possess one or more of the followingproperties: be capable of providing consistent energy absorption ofgreater or equal to about 10,000 Joules (J) during crushing, possess amodulus of greater than or equal to 1.5 gigaPascals (GPa), possess afailure strain of greater than or equal to about 60%, possess goodchemical resistance, and/or retain mechanical properties even atelevated temperatures, i.e., less than or equal to 90° C. Exemplaryplastic materials include thermoplastic materials as well ascombinations of thermoplastic materials with metal, elastomericmaterial, and/or thermoset materials. Possible thermoplastic materialsinclude polybutylene terephthalate (PBT);acrylonitrile-butadiene-styrene (ABS); polycarbonate; polycarbonate/PBTblends; polycarbonate/ABS blends; copolycarbonate-polyesters;acrylic-styrene-acrylonitrile (ASA);acrylonitrile-(ethylene-polypropylene diamine modified)-styrene (AES);phenylene ether resins; blends of polyphenylene ether/polyamide;polyamides; phenylene sulfide resins; polyvinyl chloride PVC; highimpact polystyrene (HIPS); low/high density polyethylene (L/HDPE);polypropylene (PP); expanded polypropylene (EPP); and thermoplasticolefins (TPO). For example, the plastic component can comprise Xenoy®,which is commercially available from SABIC Innovative Plastics IP B.V.The plastic component can also be made from combinations comprising atleast one of any of the above-described materials.

The overall size, e.g., the specific dimensions of the energy absorbingdevice will depend upon its location in the vehicle and its function.For example, the length (l), height (h), and width (w) of the energyabsorbing device, will depend upon the amount of space available in thedesired location of use as well as the needed energy absorption. (SeeFIG. 2) The depth and wall thicknesses of the metal component andplastic component of the energy absorbing device will also depend uponthe available space, desired stiffness, and the materials (orcombination of materials) employed. For example, the length, l, of theenergy absorbing device can be less than or equal to 500 mm,specifically, 50 mm to 250 mm, and more specifically 100 mm to 200 mm.The width, w, of the energy absorbing device can be less than or equalto 200 mm, specifically, 20 mm to 150 mm, and more specifically 40 mm to100 mm. The height, h, of the energy absorbing device can be less thanor equal to 300 mm, specifically, 60 mm to 200 mm, and more specifically80 mm to 150 mm. The length is greater than or equal to the height whichis greater than or equal to the width.

The thickness of the walls of the metal component can all be the same orcan be different to enhance stiffness in a desired direction. Forexample, one of the walls, e.g., the wall connecting two opposite walls,can have a greater/lesser thickness than the opposing walls. In someembodiments, the metal walls have a thickness of less than or equal to 5mm, specifically, 0.4 mm to 3 mm, and more specifically 0.5 mm to 1.5mm. The plastic component can have a length commensurate with the lengthof the metal component. The thickness of the walls of the plasticcomponent can be 0.5 mm to 10 mm, specifically, 2 mm to 5 mm, and morespecifically 2.5 mm to 4 mm.

As with the dimensions of the components, the density of combs isdependent upon the desired stiffness, crush characteristics, andmaterials employed. The density can be 1 to 20 combs per 100 mm²,specifically, 1 to 10 combs per 100 mm², and more specifically 1 to 5combs per 100 mm².

The energy absorbing devices disclosed herein are configured to absorb asignificant amount of impact energy when subjected to axial loadingwhile also having acceptable creep performance (i.e., less deformationupon impact). This makes these devices useful as supporting members toother vehicle components. The energy absorbing devices disclosed herein,which can be co-molded, provide an integrated energy absorbing device(e.g., a crush can) to prevent vehicle damage (e.g., damage to the bodyin white (BIW) or frame of the vehicle) upon impact. The energyabsorbing devices disclosed herein utilize various designs of aco-molded metal component and plastic component to absorb energy uponimpact, with reduced creep as compared to a wholly plastic component,and with a low cost, lightweight design. The energy absorbing device canreduce repair costs of the vehicle after impact. For example, the energyabsorbing device can reduce damage by absorbing the energy upon impactsuch that the BIW is not damaged or hardly damaged.

The energy absorbing device can be used in various locations in avehicle. Generally, the energy absorbing device can be located behindthe bumper beam and steel structure to which the bumper beam isattached, but in front of the BIW to serve as protection to the BIW fromdamage upon the application of force caused by an impact. In otherwords, between the BIW and the structure to which the bumper beamattaches. Other components which the energy absorbing device can be usedto protect include: headlamp(s), the hood, the radiator, and the vehiclerails all intended for use in front of or behind the front bumper of thevehicle; and the tailgate, deck-lid, and tail-lamps all intended for usein front of or behind the rear bumper of vehicle as well as othercomponents, and combinations comprising at least one of thesecomponents.

The energy absorbing device can be produced by several co-moldingprocesses including insert molding (e.g., over-molding) to form anenergy absorbing device comprising an integrated structure. The metalcomponent can be formed by extrusion into the desired shape (e.g., arectangular box like shape) and then the plastic component can be insertmolded into the metal component using, for example, an insert injectionmolding process. The various processes and specific details of the metalcomponent, plastic component, and assembly of the metal component andplastic component will be described in more detail with respect to thefigures.

A more complete understanding of the components, processes, andapparatuses disclosed herein can be obtained by reference to theaccompanying drawings. These figures (also referred to herein as “FIG.”)are merely schematic representations based on convenience and the easeof demonstrating the present disclosure, and are, therefore, notintended to indicate relative size and dimensions of the devices orcomponents thereof and/or to define or limit the scope of the exemplaryembodiments. Although specific terms are used in the followingdescription for the sake of clarity, these terms are intended to referonly to the particular structure of the embodiments selected forillustration in the drawings, and are not intended to define or limitthe scope of the disclosure. In the drawings and the followingdescription below, it is to be understood that like numeric designationsrefer to components of like function.

FIGS. 2, 3, 5, 7, and 8 illustrate exemplary shapes for the plasticcomponent of the energy absorbing device. Some exemplary designs for theplastic component include a layered structure comprising a plurality oflayers of triangular structures connected therebetween by planarstructures (e.g., FIG. 2), a hexagonal honeycomb structure (e.g., FIG.3), an oval honeycomb structure (e.g., FIG. 5), a diamond shapedhoneycomb structure (e.g., FIGS. 7 and 8), and so forth, as well ascombinations comprising at least one of the foregoing. FIGS. 1, 4, and 9illustrate exemplary shapes for the metal component of the energyabsorbing device. Some exemplary designs for the metal component includean open structure comprising greater than or equal to three walls (e.g.,FIG. 1) where the plastic component is molded into the cavity formed bythe walls of the metal component or a closed structure comprisinggreater than or equal to four walls (e.g., FIGS. 4 and 9) where theplastic component is molded into the cavity formed by the walls of themetal component.

Turning now to FIGS. 1 to 3, various embodiments of an energy absorbingdevice are illustrated. FIG. 1 illustrates a metal component 10. Themetal component 10 can comprise greater than or equal to three walls 12,14, 16 (e.g., a first wall, a second wall, and a third wall) forming acavity 20, e.g., a channel with a base 14, and opposing walls 12, 16extending from the base. FIG. 2 illustrates a view of a plasticcomponent 22 that is co-molded with a metal component 10 where theplastic component 22 is located in the cavity 20 formed by the walls 12,14, 16 of the metal component 10. The plastic component 22 can comprisea plurality of walls 24 forming channels throughout the plasticcomponent 22. FIG. 3 also illustrates a plastic component 28 co-moldedwith a metal component 10. The plastic component can comprise any shapethat will provide the desired properties. In FIG. 3, the plasticcomponent 28 comprises walls 34 that form the shape of a hexagonalhoneycomb. The walls 24, 34 of the plastic component 22, 28 can define aplurality of channels 26, 30.

The channels 26, 30 can extend through the plastic component 22, 28 in adirection parallel or perpendicular to any or all of the walls 12, 14,16 or any combination comprising at least one of the foregoing walls 12,14, 16 of the metal component 10. The channels 26 have an axis “A”(illustrated in FIGS. 2 and 7) that extends through the channels. In thevarious embodiments, some (FIGS. 2 and 3) or all (e.g., FIGS. 6 and 9)of the walls can be oriented parallel to the axis “A”. In FIGS. 2 and 3,the base, wall 14 that connects opposing walls 12,16, is orientedperpendicular to the axis A. Orienting the base, wall 14, perpendicularto axis A allows for ease of tooling. For example, during injectionmolding of the energy absorbing device, the core of the injectionmolding tool will move in a direction normal to the base, wall 14,thereby facilitating ease of tooling.

The metal component 10 can optionally comprise an opening(s) 18 whichallows the material of the plastic component to flow therethrough duringthe molding process to join the metal component 10 and the plasticcomponent 22, 28 to form an integral energy absorbing device 32, (e.g.,a device wherein the metal component and the plastic component are notseparable without damage to one or both components). In other words, theplastic component is inseparable from the metal component (e.g., withoutdamage to one or both components). The metal and plastic components areformed as a singular component. The opening(s) 18 can be located on anysurface (e.g., any of walls 12, 14, 16) or a combination of surfaces(e.g., any combination of walls 12, 14, 16 comprising at least one ofthe foregoing) of the metal component 10. In one embodiment, theopening(s) 18 can be located at the juncture between any two of thewalls of the metal component 10 as illustrated in FIG. 1.

The opening(s) 18 can optionally function as a crush initiator thatserves to provide localized crushing (e.g., crushing of the energyabsorbing device 30 at the crush initiator point) so that other portionsof the vehicle structure will not fail upon the application of forceduring an impact. The crush initiator enables the energy absorbingdevice 32 to absorb significant amounts of impact energy while subjectedto axial loading (e.g., upon the application of a force during acollision). When used as a supporting member to other vehicle componentsand subjected to a transverse load, the energy absorbing device 32 haslow deformation. The energy absorbing device assists vehicle bumpers inbeing able to attain the RCAR, Allianz, and Thatcham structural testprotocols for bumpers. Additionally, the energy absorbing device iscapable of assisting vehicle bumpers and body structure in meeting highspeed front crash safety protocols such as FMVSS, IIHS, and EuroNCAP(e.g., greater than or equal to 20 miles per hour). Creep of the energyabsorbing device and bumper beam is measured by subjecting the energyabsorbing device and bumper beam to high temperature loading, i.e., lessthan or equal to 90° C. for a time period of 600 to 1,000 hours orgreater. The downward deflection due to the gravitational load of thebumper beam of the energy absorbing device is measured. Material testingfor creep of the plastic component can be according to ASTM D2990-09 andISO 899, while that the for the metal component can be according to canfollow ASTM E139-06.

The metal component 10 can also optionally comprise additional walls(e.g., a fourth wall, fifth wall, and/or sixth wall (not illustrated))that enclose the cavity and create a closed box shaped structure aspreviously described.

Turning now to FIGS. 4 through 7, additional embodiments of an energyabsorbing device 50 are illustrated. FIG. 4 illustrates a metalcomponent 40 comprising walls (e.g., first wall 42, second wall 44,third wall 46, and fourth wall 48) forming a cavity 54 therein. Themetal component 40 comprises a closed box shaped structure as previouslydescribed. The metal component 40 can comprise an aperture(s) 52 on atleast one wall that, during the forming of the energy absorbing device50, allows material from the plastic component 56, e.g., piece 60, toflow therethrough and create plastic element(s) 62 (which can be thesame or a different material as the plastic component) on at least onewall of the metal component 40. The element(s) 62 lock the plasticcomponent within the metal component, thereby preventing the removalthereof (without breaking the element off of the plastic component).Three thermoplastic pieces 62 are illustrated in FIG. 6.

Any of the walls (e.g., walls 42, 44, 46, and/or 48) of the metalcomponent 40 or any combination of the walls of the metal component 40can further optionally comprise a crush initiator(s) 64 to providelocalized crushing at that point to prevent other portions of thevehicle structure (e.g., BIW) from failing upon the application of forceduring an impact. For example, the crush initiator(s) 64 can be locatedat the junction between walls 42 and 46, 46 and 44, 44 and 48, or 42 and48. Any number of crush initiators 18 can be present, provided that thenumber of crush initiators 18 is sufficient to provide localizedcrushing at those points.

FIG. 5 illustrates a plastic component 56 which can be co-molded withthe metal component 40 and located in the cavity 54 created by the wallsof the metal component 40. The plastic component 56 can comprise aplurality of members 58 containing channels 26 therein. FIG. 5illustrates a plurality of oval shaped members, while FIG. 7 illustratesa plurality of diamond shaped members.

The assembled energy absorbing device 50 is illustrated by FIG. 6. Theplastic piece(s) 62 can be oriented such that a wall of the metalcomponent 40 is perpendicular to the axis of the channels 26 of theplastic component 56 after forming In another embodiment, thethermoplastic piece(s) 62 can be oriented such that a wall of the metalcomponent 40 is parallel to the axis of the channels 26 of the plasticcomponent 56.

In an alternate embodiment, illustrated by FIG. 7, a diamond shapedplastic component 66 is illustrated. The plastic component 66 comprisesmembers 67 defining channels 26 therein. The plastic component 66 can beco-molded with metal component 40 to provide a single unit assembledenergy absorbing device (not illustrated).

FIGS. 8 and 9 illustrate a further embodiment of a plastic component 70,metal component 72, and assembly of an energy absorbing device 74. Theplastic component 70 can comprise a plurality of members 76 definingchannels 26 therein. In FIG. 8 a plurality of diamond shaped members areillustrated, although any shape for the members 76 can be utilized. Forexample, the members 76 can comprise any shape including, but notlimited to, oval, circular, diamond, triangular, square, rectangular,hexagonal, honeycomb, pentagonal, elliptical, etc., as well ascombinations comprising at least one of the foregoing.

An energy absorbing device 74 is illustrated by FIG. 9. The channels 26of the plastic component 70 comprise an axis illustrated by the line C-Cin FIG. 8. The metal component 72 comprises greater than or equal tofour walls such that a wall of the metal component 72 is parallel to theaxis of the channels 26. The metal component 72 can comprise anaperture(s) 52 (not illustrated) on at least one wall that, during theforming of the energy absorbing device 74, allows material from theplastic component 70, e.g., piece 60 illustrated in FIGS. 7 and 8, toflow therethrough and create plastic element(s) 62 (which can be thesame or a different material as the plastic component) on at least onewall of the metal component 72. The element(s) 62 lock the plasticcomponent within the metal component, thereby preventing the removalthereof (without breaking the element off of the plastic component).Three thermoplastic pieces 62 are illustrated in FIG. 9.

The energy absorbing device 74 can be formed by co-molding the plasticcomponent 70 and metal component 72 as previously described. Any of thewalls of the metal component 72 or any combination of the walls of themetal component 72 can further optionally comprise a crush initiator(s)64 (not illustrated) to provide localized crushing at that point toprevent other portions of the vehicle structure (e.g., BIW) from failingupon the application of force during an impact.

A method of forming an energy absorbing device 80 comprising a plasticcomponent 82 and a metal component 84 is illustrated by FIGS. 10, 11,and 12. FIG. 10 illustrates an assembled energy absorbing device 80where plastic from the plastic component 82 is allowed to flow throughan aperture(s) 86 of the metal component 84 during the molding processto form a single piece assembled energy absorbing device 80. FIG. 12illustrates a view along line D-D of FIG. 11 where it can be seen howthe plastic of the plastic component 82 flows through the aperture(s) 86of the metal component 84. The plastic component 82 further compriseswalls defining channels 26 therein.

In an embodiment, an energy absorbing device comprises: a metalcomponent comprising greater than or equal to three walls forming ametal component channel; and a plastic component having a honeycombstructure with a plurality of walls defining comb channels therein. Theplastic component is located in the metal component channel forming acrash can. The plastic component is inseparable from the metal componentwithout damage to the metal component and/or the plastic component. Theenergy absorbing device can be configured for impact energy absorptionin a vehicle.

In one embodiment, a method of making an energy absorbing device cancomprise: co-molding the metal component and the plastic component toform a crash can. The metal component can comprise greater than or equalto three walls forming a metal component channel and the plasticcomponent can have a honeycomb structure with a plurality of wallsdefining comb channels therein.

In one embodiment, a vehicle can comprise: a vehicle component; anenergy absorbing device located adjacent to the vehicle component. Theenergy absorbing device can comprises: a metal component comprisinggreater than or equal to three walls forming a metal component channel;and a plastic component having a honeycomb structure with a plurality ofwalls defining comb channels therein. The plastic component can belocated in the metal component channel and is inseparable therefromwithout damage to the metal component and/or the plastic component.

In the various embodiments, (i) the metal component can comprise afourth wall that encloses the channel; and/or (ii) a wall of the metalcomponent can comprise an aperture, and wherein plastic material fromthe plastic component can be located in the aperture; and/or (iii) awall of the metal component can further comprise a crush initiator;and/or (iv) the crush initiator can be located on a corner of the metalcomponent, at the intersection of two walls; and/or (v) the combchannels can comprise a shape selected from the group consistingcircular, oval, square, rectangular, triangular, diamond, pentagonal,hexagonal, heptagonal, and octagonal, and combinations comprising atleast one of the foregoing; and/or (vi) all of the walls of the metalcomponent can be parallel to an axis of the channels; and/or (vii) twoopposing walls can be parallel to an axis of the channels, and a wallconnecting the two opposing walls can be perpendicular to the axis;and/or (viii) the metal component can comprise at least two sets ofopposing walls, and wherein each set of the opposing walls joins theother set of opposing walls together; and/or (ix) the energy absorbingdevice can further comprise a length that is greater than or equal to aheight which is greater than or equal to a width, and wherein the lengthis less than or equal to 500 mm; and/or (x) the height can be less thanor equal to 300 mm, and the width can be less than or equal to 200 mm;and/or (xi) the metal component can further comprise a cavity on a sideof a wall opposite the plastic component, wherein the cavity has anaperture through the wall, and where a plastic element in the cavityconnects to the plastic component through the aperture; and/or (xii)plastic from the plastic component can extend through an aperture in themetal component; and/or (xiii) the plastic component can be located inthe metal component channel and be inseparable therefrom without damageto the metal component and/or the plastic component; and/or (xiv) theco-molding can comprise a process selected from the group consisting ofinjection molding, insert molding, and combinations comprising at leastone of the foregoing; the method can further comprise flowing plasticthrough an aperture in the metal component; and/or (xv) the plastic canflow into a cavity on a side of the metal component wall opposite theplastic component, binding the metal component and plastic componenttogether; and/or (xvi) the method can further comprise extruding plasticto form the plastic component; and/or (xvii) the vehicle component canbe selected from the group consisting of the body in white (also knownas the body in black), and wherein the energy absorbing device islocated between the vehicle component and to which a bumper beamattaches.

The energy absorbing device disclosed herein offers efficient energyabsorbing characteristics while being lightweight and less expensivethan other all metal structures. The energy absorbing device disclosedherein also offers a single piece assembled energy absorbing devicewhich can be formed by processes such as injection molding to make theenergy absorbing device less expensive than all plastic extrudedstructures. Additionally, the integration of the metal component and theplastic component provides higher resistance to deformation than allplastic extruded or injection molded structures while providingefficient energy absorption characteristics as compared to all plasticinjection molded structures.

All ranges disclosed herein are inclusive of the endpoints, and theendpoints are independently combinable with each other (e.g., ranges of“up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, isinclusive of the endpoints and all intermediate values of the ranges of“5 wt. % to 25 wt. %,” etc.). “Combination” is inclusive of blends,mixtures, alloys, reaction products, and the like. Furthermore, theterms “first,” “second,” and the like, herein do not denote any order,quantity, or importance, but rather are used to d one element fromanother. The terms “a” and “an” and “the” herein do not denote alimitation of quantity, and are to be construed to cover both thesingular and the plural, unless otherwise indicated herein or clearlycontradicted by context. The suffix “(s)” as used herein is intended toinclude both the singular and the plural of the term that it modifies,thereby including one or more of that term (e.g., the film(s) includesone or more films). Reference throughout the specification to “oneembodiment”, “another embodiment”, “an embodiment”, and so forth, meansthat a particular element (e.g., feature, structure, and/orcharacteristic) described in connection with the embodiment is includedin at least one embodiment described herein, and may or may not bepresent in other embodiments. In addition, it is to be understood thatthe described elements may be combined in any suitable manner in thevarious embodiments.

While particular embodiments have been described, alternatives,modifications, variations, improvements, and substantial equivalentsthat are or may be presently unforeseen may arise to applicants orothers skilled in the art. Accordingly, the appended claims as filed andas they may be amended are intended to embrace all such alternatives,modifications variations, improvements, and substantial equivalents.

What is claimed is:
 1. An impact device, comprising: a metal componentcomprising greater than or equal to three walls forming a metalcomponent channel; and a plastic component having a honeycomb structurewith a plurality of walls defining comb channels therein; wherein thecomb channels are oriented perpendicular to at least one of the threewalls, and the plastic component is inseparable from the metal componentwithout damage to at least one of the metal component and the plasticcomponent; wherein a wall of the metal component comprises an aperture,and wherein plastic material from the plastic component is located inthe aperture; and wherein the impact device can be located in a vehicleto prevent damage to the body in white upon impact.
 2. The impact deviceof claim 1, wherein the comb channels comprise a shape selected from thegroup consisting circular, oval, square, rectangular, triangular,diamond, pentagonal, hexagonal, heptagonal, and octagonal, andcombinations comprising at least one of the foregoing.
 3. The impactdevice of claim 1, wherein two opposing walls are parallel to an axis ofthe channels, and a wall connecting the two opposing walls isperpendicular to the axis.
 4. The impact device of claim 3, wherein theplastic component located in the metal component channel forms a crashcan.
 5. The impact device of claim 4, wherein the plastic component isinseparable from the metal component without damage to the metalcomponent, the plastic component, or both the metal component and theplastic component.
 6. The impact device of claim 1, wherein the plasticcomponent is inseparable from the metal component without damage to themetal component, the plastic component, or both the metal component andthe plastic component.
 7. The impact device of claim 1, wherein theplastic component located in the metal component channel forms a crashcan.
 8. An impact device, comprising: a metal component comprisinggreater than or equal to three walls forming a metal component channel;and a plastic component having a honeycomb structure with a plurality ofwalls defining comb channels therein; wherein the comb channels areoriented perpendicular to at least one of the three walls, and theplastic component is inseparable from the metal component without damageto at least one of the metal component and the plastic component;wherein a wall of the metal component comprises an aperture, and whereinplastic material from the plastic component is located in the aperture;wherein the plastic component is inseparable from the metal componentwithout damage to the metal component, the plastic component, or boththe metal component and the plastic component; wherein two opposingwalls are parallel to an axis of the channels, and a wall connecting thetwo opposing walls is perpendicular to the axis; and wherein the impactdevice can be located in a vehicle to prevent damage to the body inwhite upon impact.
 9. A method of making an impact device, comprising:forming a metal component comprising greater than or equal to threewalls forming a metal component channel; forming a plastic component,wherein the plastic component has a honeycomb structure with a pluralityof walls defining comb channels therein wherein the comb channels thatare oriented perpendicular to at least one of the three walls, and theplastic component is inseparable from the metal component without damageto at least one of the metal component and the plastic component; andflowing plastic through an aperture in the metal component to form animpact device configured for use in a motor vehicle.
 10. The method ofclaim 9, wherein the plastic flows into a cavity on a side of the metalcomponent wall opposite the plastic component, binding the metalcomponent and plastic component together.
 11. The method of claim 9,wherein two opposing walls are parallel to an axis of the channels, anda wall connecting the two opposing walls is perpendicular to the axis.12. The method of claim 11, wherein the plastic component located in themetal component channel forms a crash can.
 13. The method of claim 12,wherein the plastic component is inseparable from the metal componentwithout damage to the metal component, the plastic component, or boththe metal component and the plastic component.
 14. The method of claim9, wherein the plastic component is inseparable from the metal componentwithout damage to the metal component, the plastic component, or boththe metal component and the plastic component.
 15. The method of claim9, wherein the plastic component located in the metal component channelforms a crash can.